Method for producing a plastic composite element

• US 6,932,927 B2
• Filed: 02/22/2001
• Issued: 08/23/2005
• Est. Priority Date: 02/24/2000
• Status: Expired due to Fees

• Current Assignee: International Automotive Components Group North America (Lear Corporation)
• Original Assignee: Lear Corporation
• Inventors: Fusseder, Josef
• Primary Examiner(s): Kuhns, Allan R.
• Application Number:
  US10/204,677
• Publication Number:
  US 20030143385A1
• Time in Patent Office: 1,643 Days
• Field of Search: 264/45.1, 264/46.4, 264/46.6, 264/46.8, 264/255, 264/320
• US Class Current: 264/46.4
• CPC Class Codes: B29C 44/0469 provided with physical separators between the different materials, e.g. separating layers, mould walls
• CPC Class Codes: Y10T 428/24983 Hardness
• CPC Class Codes: Y10T 428/249953 Composite having voids in a component [e.g., porous, cellular, etc.]
• CPC Class Codes: Y10T 428/249981 Plural void-containing components
• CPC Class Codes: Y10T 428/249987 With nonvoid component of specified composition
• CPC Class Codes: Y10T 428/249991 Synthetic resin or natural rubbers

Abstract

The present invention relates to a method for producing a plastic composite element (1), in particular as an interior lining element for a motor vehicle, with an outer covering (2) being lined with a foamable plastic, characterized in that the outer covering (2) is lined at least partially with a flexible foam (3), that the flexible foam (3) is subsequently lined with a rigid foam (5) with a separating means being placed thereinbetween, and that a shaped part (4) which can be prefabricated is used as the separating means which by virtue of the mechanical properties of its material and/or its shape prevents the rigid foam (5) from penetrating the flexible foam (3) and/or prevents a deformation of the outer covering (2), and such a plastic composite element (2).

Claims

1. A method for producing a plastic composite element (1) as an interior lining element for a motor vehicle, with an outer covering (2) being lined with a foamable plastic, characterized in that said outer covering (2) is lined at least partially with a flexible foam (3), that said flexible foam (3) is subsequently lined with a rigid foam (5), with a separating means being placed thereinbetween, and that a shaped part (4) which can be prefabricated is used as said separating means which by virtue of the mechanical properties of its material and/or its shape prevents said rigid foam (5) from penetrating said flexible foam (3) and/or prevents a deformation of said outer covering (2) and wherein a portion of said shaped part (4) contacts said outer covering (2) and is connected thereto.

2. The method according to claim 1, characterized in that said shaped part (4) is produced by deep drawing.

3. The method according to claim 2, characterized in that said shaped part (4) is made of acrylic butadiene styrene, polyvinyl chloride or polystyrene with an initial thickness of 0.1 to 0.7 mm.

4. The method according to claim 1 wherein during lining of said outer covering (2), a flexible foam material forming said flexible foam (3) is applied to a back side (2a) of said outer covering (2) which is laid into a lower mold (6) and subsequently, before or during foaming of said flexible foam material, said shaped part (4) which is mounted on an upper mold (7) is brought into contact with said flexible foam material.

5. The method according to claim 1 wherein said shaped part (4) includes an edge portion that is brought into a contact with said outer covering (2) and connected thereto.

6. The method according to claim 1 wherein said flexible foam (3) is a polyurethane foam having a specific weight from 0.11 to 0.18 g/cm³.

7. The method according to claim 2 wherein during lining of said outer covering (2), a flexible foam material forming said flexible foam (3) is applied to a back side (2a) of said outer covering (2) which is laid into a lower mold (6) and subsequently, before or during foaming of said flexible foam material, said shaped part (4) which is mounted on an upper mold (7) is brought into contact with said flexible foam material.

8. The method according to claim 3 wherein during lining of said outer covering (2), a flexible foam material forming said flexible foam (3) is applied to a back side (2a) of said outer covering (2) which is laid into a lower mold (6) and subsequently, before or during foaming of said flexible foam material, said shaped part (4) which is mounted on an upper mold (7) is brought into contact with said flexible foam material.

9. The method according to claim 2 wherein said shaped part (4) includes an edge portion that is brought to contact with said outer covering (2) and connected thereto.

10. The method according to claim 3 wherein said shaped part (4) includes an edge portion that is brought into contact with said outer covering (2) and connected thereto.

11. The method according to claim 4 wherein said shaped part (4) includes an edge portion that brought into contact with said outer covering (2) and connected thereto.

12. The method according to claim 2 wherein said flexible foam (3) is a polyurethane foam having a specific weight from 0.11 to 0.18 g/cm³.

13. The method according to claim 3 wherein said flexible foam (3) is a polyurethane foam having a specific weight from 0.11 to 0.18 g/cm³.

14. The method according to claim 4 wherein said flexible foam (3) is a polyurethane foam having a specific weight from 0.11 to 0.18 g/cm³.

15. The method according to claim 5 wherein said flexible foam (3) is a polyurethane foam having a specific weight from 0.11 to 0.18 g/cm³.